Product Catalogue - Asahi Diamond · A grinding enquiry sheet is included on the last page of this...

Product Catalogue

Engineering

Notes...

Contents

Asahi Diamond Industrial Australia - Our Story …………………………………………..……...………….. 1

Diamond and CBN Wheels ……………………………………………………………………………………. 3

Diamond vs. CBN ………………………………………………………………………………………………. 4

Resin Bond Wheels …………………………………………………………………………………………….. 5

Metal Bond Wheels ……………………………………………………………………………………………. 6

Electroplated Wheels …………………………………………………………………………………………... 7

Wheel Selection ………………………………………………………………………………………………… 8

Grit Selection ………………………………………………………………………………………………….… 9

Grain Size Conversion Chart ………………………………………………………………………………… 10

Basic Shape Code of Wheel …………………………………………………………………………………... 11

Standard Resin Bond Wheels ……………………………………………………………………………........ 13

Diamond Dressing Tools …………………………………………………………………………………….… 29

Single Point Diamond Dressers ……………………………………………………………………………..… 30

Chisel Form Diamond Dressers …………………………………………………………………………….… 31

Blade Type Diamond Dressers ……………………………………………………………………………… 32

Impregnated Diamond Dressers ………………………………………………………………………………. 33

Multipoint Diamond Dressers ………………………………………………………………………………..… 34

Handheld Diamond Dressers ………………………………………………………………………………….. 35

Electroplated Files …………………………………………………………………………………………….... 36

Internal Grinders ………………………………………………………………………………………………… 37

Countersink Tools 90 deg ……………………………………………………………………………………. 38

Metal Bond Core Drills ……………………………………………………………………………………….… 39

PCD and CBN Inserts and Tools ……………………………………………………………………………… 40

Diamond Lapping Compound – Premium SS Range …………………………………………………….… 41

Grinding Wheel Care and Application ………………………………………………………………………… 42

Speed Chart ……………………………………………………………………………………………………... 47

Wheel Enquiry Form ………………………………………………………………………………………….… 48

1

Introduction

Asahi Diamond Industrial is one of the world leaders in Diamond tooling supporting the Engineering, Construction and Mining sectors with high quality Diamond products that are reliable and cost effective. Technology advances are so rapid that one year old technology may be considered redundant. To keep pace with these technological advances Asahi Diamond continually develops and modifies high precision, highly efficient tools, while promoting application development. Used in a wide range of applications, Diamond tools are used within the mining sector for drilling and geotechnical operations where high quality and reliability is required. They play an integral role in preventing excessive noise and protecting the environment. They are also used for dismantling buildings and bridges, seismic strengthening, upgrading infrastructure, and processing of various types of stone. Asahi Diamond Industrial through a stable supply of raw materials and through a constant development process can guarantee stable, high quality products across the range.

Our Story

In 1947 Triefus Company Ltd. became a public company and its shares were quoted on the London Stock Exchange. At this time there became an increasing awareness of the importance of Diamond tools of all types in the modern industrial world. An engineer was appointed to the staff and following a small investment Triefus and Company Limited commenced manufacturing single point Diamond dressers. By 1949 a small manufacturing company was established which made its first take-over in 1952. Expansion became rapid and profits grew. Also in 1949 a survey of Diamond tool and drilling potential was undertaken in Australia. Sales of rough Diamond commenced in 1950 and a small manufacturing plant set up the following year. Similar plants were established in other countries including France and India. World demand for industrial Diamond products increased dramatically and the close links already established with industrial Diamond merchants and product manufacturers resulted in rapid growth for the Triefus group. A particularly close association developed between the Triefus UK manufacturing company and the Asahi Diamond Industrial Co. Limited which had been established in Tokyo in 1937. This close association was later expanded to include cross shareholdings and eventually led to Asahi taking control of the Triefus Group in 1990.

Asahi Today

The Asahi group is one of the world’s largest manufacturers of industrial Diamond products with an enviable reputation for service and expertise. Asahi Australia were manufacturing and marketing industrial Diamond products right up until 2002 at the principal office and factory located in Mona Vale NSW, a northern beaches suburb of Sydney. Sales Offices are still maintained at these premises with products being sourced from our Group Companies in Japan, France, South Korea, Taiwan and Indonesia, with our products and services being used in various Diamond application areas for:

- Mining and Exploration

- Precision Engineering - Construction Projects

2

All of our mining products are manufactured in our state of the art Jakarta factory, where our first factory was built in 1996 predominantly to supply and service the South-East Asian market.

Our Australian factory ceased production in 2002 and all our equipment and manufacturing expertise was transferred in total to our Jakarta plant at this time, and now produces our extensive range of mining and exploration products that we supply globally. We are now in our third built factory in Jakarta having grown out of our previous two, and have recently been quality accredited with ISO9001 Certification.

Our Promise to You

In addition to aiming to exceed your expectations we promise to offer our customers:

Service: A personalized service from your first point of contact - access to unparalleled advice from our

team of experts and products that are delivered on time.

Quality: Technologically advanced high performing products that are built to last.

Price: Exceptional prices on exceptional quality products.

Honesty: To deliver what we promise and to treat all our customers with honesty and integrity.

Short Facts

Global Head Office: Tokyo, Japan.

Number of employees: 2,147 worldwide.

Manufacturing: Indonesia, Japan, Taiwan.

Global presence: Australia, Japan, Indonesia, Thailand, China, Taiwan, United Stated of America,

Europe, Russia, Mongolia, Singapore, Malaysia, Vietnam, Cambodia, Philippines, South America, South Africa, DK Congo, Myanmar, India.

3

Diamond and CBN Wheels Grinding is an indispensible step of the manufacturing process. Asahi Diamond manufactures a comprehensive range of “super-abrasive wheels” using the highest quality Diamond and CBN (Cubic Boron Nitride) particles. Super-abrasive wheels display the following excellent characteristics unfound in conventional abrasives:

Faster cutting speeds

Higher heat and wear resistance

Improved accuracy and surface finish

Minimal dust creation These characteristics provide improved safety, increased operation efficiency and lower tool costs.

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

10000

Kn

oo

p H

ard

ness

Knoop Hardness

0

1

2

3

4

5

6

7 cal/

(sec)(

cm

2)(

oC

/cm

)

Thermal Conductivity

-40

-30

-20

-10

0

10

100 200 300 400 500 600 700 800 900 1000 1100 1200 Weig

ht C

han

ge (

%)

Temperature (C)

Thermal Stability

Diamond (in the air) CBN (in the air) CBN (in steam)

4

Diamond vs. CBN Diamond is the hardest material known to man and has great abrasion resistance. These properties make Diamond wheels the preferred choice of abrasive when grinding materials such as sintered carbide, glass, ceramics and other hard non-ferrous materials. CBN is a more suitable abrasive than Diamond when grinding ferrous materials. It has a heat resistance of 1200˚C, while Diamond begins to oxidize at 600˚C. Unlike Diamond, CBN does not chemically react in a negative manner to iron. Therefore CBN wheels are used when grinding steel alloys such as carbon tool steel, HSS, die steel and other hard alloys.

Materials to be Ground

CBN Diamond

t-

5

Resin Bond Wheels Resin bond is usually made with a heat-cured resin mostly composed of phenolic resin. They provide excellent grinding ability, surface finish and minimal chipping. Resin bond super abrasive wheels are widely applied to difficult to machine materials such as cemented carbide, ceramics, glass, and silicon as well as ferrous materials such as tool steel, HSS, die steel and other hard metals.

Characteristics of resin bond wheels

Resin bond usually has added organic and inorganic materials and metal filler. These materials are added to the phenolic resin in order to control wear resistance, heat resistance, grit retention and lubrication.

Resin bond wheels are low in Young’s modulus (elastic modulus). As a result excellent characteristics are achieved in processing efficiency, free cutting ability, surface finish and minimization of chipping.

In comparison to metal bond wheels, resin bond wheels have weaker adhesion between the grit and the bond. This results in a much better cutting ability when processing hard to grind materials such as cermets, ceramics etc.

The Diamond and CBN abrasives used in resin bond wheels are irregular shaped and easy to micro fracture. This allows new cutting edges to be constantly created while grinding.

Resin bond wheels are typically used for wet grinding, but they can be used for dry grinding by adding some filler during the manufacturing process. The use of this filler reduces heat generated in the grinding process and improves cutting ability.

Applications of Resin Bond Diamond wheels

Resin bond Diamond wheels are most commonly used for precision grinding of cemented carbide, cermets and ceramics.

Because of the bond elasticity they are used for finish grinding of silicon, glass, ceramic made electrical parts etc. where excellent surface finishes are required.

Application of Resin Bond CBN wheels

Resin bond CBN wheels are suitable for grinding ferrous metals such as cast iron, HSS and sintered iron.

CBN is superior in precision grinding applications when compared to conventional abrasives. They wear less than conventional abrasives and are suitable for processing hard to machine materials due to the hardness of the CBN particles. Higher thermal conductivity also allows for less heat to be absorbed by the work piece during the grinding process.

6

Metal Bond Wheels Metal bond is a binding material made of metallic powders comprising copper, tin, iron, cobalt etc. Metal Bond Wheels have excellent grit retention and wear resistance compared to other bond types.

Characteristics of Metal Bond Wheels

Divided into three major types:

1. Bronze type – superior in grinding ability

2. Cobalt type – superior in wheel life

3. Steel type – stands between bronze and cobalt types regarding grinding capabilities

Excellent grit retention and wear resistance in comparison to resin bond wheels. Long tool life is achieved when processing difficult to machine materials such as glass, ceramics, semi-conductor electron materials etc.

Due to its electric conductivity it can be used for electrolytic grinding and electrical discharge grinding (EDM).

Applications of Diamond Metal Bond Wheels

With excellent grit retention and wear resistance Diamond metal bond wheels are used for rough/semi finishing difficult to machine materials such as: glass ceramics, ferrite, fireproof materials, stone etc. Exceptional results are achieved during chamfering processes.

Widely used for form/profile grinding in which Diamond wheels are required to keep profile.

Applications of CBN Metal Bond Wheels

Excellent wear resistance of the bond gives excellent efficiency in rough grinding of unhardened steel materials.

Highly recommended for grooving of hardened steel and grinding which requires high efficiency and accuracy.

7

Electroplated Wheels Electroplated wheels bring stable performance in grinding accuracy, grinding ability and wheel life. They have an excellent reputation in a variety of applications.

Characteristics of Electroplated Wheels

Constant in grinding ability and can be used for many materials because of the high amount of abrasive material protruding from the bond.

Capable of holding form at low cost, therefore suitable for form wheels.

Best suited to produce small volume production in wide ranges. Electroplated wheels are inexpensive and wheel life is shorter than other bonds because they are typically a single layer of abrasive material.

The consumed abrasive can be stripped and re-plated using the existing core (provided it is not damaged).

Structure of Electroplated Area

8

Wheel Selection To successfully meet customers’ requirements during wheel selection the following information is required:

1. Shape and dimensions of the wheel

2. Grit size

3. Concentration

4. Bond

5. Additional information regarding:

a) Working condition

b) Work piece material

c) Required finish

d) Any special requirements

A grinding enquiry sheet is included on the last page of this catalogue to help in providing the required information to your Asahi representative.

9

0

2

4

6

8

10

12

14

0 50 80 100 120 140 170 200 230 270 325 400 500 600 800 1000

Su

rface R

ou

gh

ness R

y u

m

Mesh size

Ceramics (Diamond)

Electroplated Metal Vitrified Resin

0

2

4

6

8

10

12

14

16

18

20

0 50 80 100 120 140 170 200 230 270 325 400 500 600 800 1000

Su

rface R

ou

gh

ness R

y u

m

Mesh size

Hardening Steel (CBN)

Metal Electroplated Vitrified Resin

Grit Selection

10

Grain Size Conversion Chart

Please note: Products listed in this Asahi catalogue use the mesh size as standard in product

descriptions.

Mesh Size Average Diameter

(µm) JIS U.S.A. B.S.S. FEPA

50 297 50 / 60 50 / 60 50 / 60 D301

60 250 60 / 85 60 / 85 60 / 85 D252

80 177 85 / 100 85 / 100 85 / 100 D181

100 149 100 / 120 100 / 120 100 / 120 D151

120 125 120 / 140 120 / 140 120 / 140 D126

140 105 140 / 170 140 / 170 140 / 170 D107

170 88 170 / 200 170 / 200 170 / 200 D91

200 74 200 / 230 200 / 230 200 / 240 D76

230 62 230 / 270 230 / 270 D64

270 53 270 / 325 270 / 325 240 / 300 D54

325 44 325 / 400 325 / 400 D46

400 37 36 - 54µ M40

600 28 22 – 36µ 27 – 40µ M25

1000 15 12 - 22µ 12 – 18µ M16

1500 10 8 – 12µ 8 – 12µ M10

2000 8 5 – 12µ

2500 6 4 – 8µ 4 – 8µ M6.3

3000 5 2 – 6µ 2 - 6µ

11

Basic Shape Code of Wheel

13

Standard Asahi Resin Bond Wheels

1A1

D T X H Grit Conc.

Stock Code

50 12 3 12.70 SDC120 R75 4181

100 4 4 31.75 SDC140 R75 25-0100

100 4 5 20 SDC120 R75 6265

100 4 5 31.75 SDC120 C75 25-0148

100 4 5 31.75 SDC120 R75 6258

100 6 6 31.75 SDC170 R75 2834

100 6 6 32 SDC140 R100 25-0137

150 6 3 31.75 SDC140 N75 4183

150 10 3 31.75 SDC230 R75 25-0179

175 7 8 31.75 SDC120 R75 25-175

200 10 3 60 SDC200 R100 25-0185

350 12 3 127 SDC140 N75 9719

D T X H Grit Conc. Stock Code

50 10 3 12.70 CBN B80 N100 4567

125 2 6 32 CBN B60 R75 9361

150 6 6 31.75 CBN B140 R100 25-0287

200 10 3 60 CBN B140 R100 25-0216

14

1A1R

D T X H Grit Conc.

Stock Code

150 1 3 31.75 SDC120 P75 1305

150 1 5 31.75 SDC100 N100 6926

200 1.5 5 20 SDC100 N100 25-0218

D T X H Grit Conc. Stock Code

203 1.5 5 31.75 CBN B80 R100 25-0215

15

3A1

D U X T J H Grit Conc.

Stock Code

100 4 3 15.5 85 25(k) SDC220 N75 25-0173

450 20 3 45 400 254 SDC80 N100 25-04501

16

4A2

D W X T H Grit Conc.

Stock Code

100 5 3 10 25(k) SDC400 R100 25-01021

115 3.5 6 11 31.75 SDC120 C75 25-005

125 3 3.8 14 32 SDC250 R100 25-012520

125 5 1 12 32 SDC200 R75 25-012518

125 5 2 12 32 SDC220 R75 25-012513

150 5 2 5 31.75 SDC325 R75 25-01523

150 5 3 7 31.75 SDC120 C75 25-0482

150 6 1.5 10.5 31.75 SDC240 R100 25-01515

150 6 2 8 31.75 SDC150 R75 25-01510

150 6 3 13 31.75 SDC150 R75 25-01509

150 6 3 18 31.75 SDC200 R100 25-0660

200 6.5 2 13 31.75 SDC230 R100 25-0222

D W X T H Grit Conc. Stock Code

150 6 3 18 20 CBN B140 R100 25-0666

150 6 3 18 31.75 CBN B140 R100 25-0244

17

6A2


Stock Code

125 5 10 20 32 SDC270 C125 25-01592

130 10 10 35 12 SDC230 C75 25-00230

150 15 10 40 11 SDC270 C75 25-270

150 15 10 40 11 SDC700 C75 25-700

150 3 8 16 31.75 SDC120 C75 25-01045

150 4 4 18 20 SDC200 R100 25-0444

200 6 8 30 50 SDC140 L75 9323


100 4 9 36 20 CBN B140 R100 25-0119

125 6 6 40 31.75 CBN B170 R100 6598-1

200 6 8 30 50 CBN B60 N75 9326

6A2B (with bolt holes)


125 4 9 18 20 SDC200 R100 9042


125 4 9 18 20 CBN B140 N100 5720

125 4 9 18 20 CBN B80 R100 25-0289

18

6A9

D U X T H Grit Conc.

Stock Code

100 10 3.5 29 20 CBN B100 R100 25-05020

19

6VV9

D W1 + W2 X T H Grit Conc.

Stock Code

100 2.5+2.5 6 20 25(k) SDC120/325 R100/75 1510

100 2.5+2.5 6 20 25(k) SDC170/600 R100/75 1510-1

125 2.5+2.5 6 17 32 SDC120/325 R100/75 25-01258

125 2.5+2.5 10 20 32 SD200/400 C125/100 25-01050

125 2.5+2.5 10 20 32 SDC200/600 C125/100 25-01055

D W1 + W2 X T H Grit Conc. Stock Code

125 2.5+2.5 6 20 32 CBN B120/325 R100/75 25-01263

NOTE: (k) = Keyed

20

11A2


Stock Code

100 10 3 40 31.75 SDC120 N75 8596


150 6 5 45 31.75 CBN B60 N75 25-0272

150 6 6 45 31.75 CBN B120 R100 25-01560

21

11V9

D U X T H Grit Conc. Stock Code

50 6 1.5 25 14 SDC400 R100 25-0052

50 6 3 25 10 SDC120 R75 25-00502

75 10 3 30 31.75 SDC200 C75 25-0754

100 10 3 35 31.75 SDC120 C75 3082

100 10 3 35 31.75 SDC230 C75 3083

100 10 3 35 31.75 SDC325 R75 25-01037

D U X T H Grit Conc. Stock Code

50 6 1.5 25 14 CBN B80 R75 25-0051

75 10 3 30 31.75 CBN B120 R75 25-759

100 10 2 35 31.75 CBN B230 R75 25-01027

100 10 3 40 31.75 CBN B120 N75 5000

125 10 3 40 31.75 CBN B60 R100 2244

150 12 5 50 31.75 CBN B60 N75 7311

22

12A2

D W X T S H Grit Conc.

Stock Code

100 6 2 12 20 31.75 SDC230 R100 25-0106

125 6 3 16 20 32 SDC220 R75 2832

125 6 6 18 20 32 SDC220 R75 7184

125 6 3 16 20 20 SDC140 R75 25-01251

125 6 3 16 20 31.75 SDC400 R100 2339

125 3 2 20 45 20 SDC250 N50 3461

150 6 3 18 20 31.75 SDC240 R75 9753

150 6 3 16 20 31.75 SDC120 R75 7612

150 6 3 16 20 31.75 SDC200 R100 25-0521

150 10 3 16 20 31.75 SDC170 R75 25-01556

175 6 3 19 20 31.75 SDC80 R100 8800

200 10 6 20 20 31.75 SDC120 C75 25-09010

250 10 6 20 20 31.75 SDC120 C75 25-09040

D W X T S H Grit Conc. Stock Code

100 6 3 30 45 32 CBN B170 C75 25-0143

150 6 3 18 20 31.75 CBN B120 R75 25-01533

23

12B9


Stock Code

100 6 4 14 20(k) SDC200 R75 25-01008


100 6 6 14 32 CBN B120 N100 25-01026

24

12V2

D W X T S H Grit Conc.

Stock Code

100 6 4 13 20 25(k) SDC325 C125 25-01210

125 2 5 12 20 32 SDC325 C125 25-01277

125 4 3 12 20 32 SDC325 N125 25-01257

150 4 2 14 30 32 SDC325 C125 25-01541

160 7 3 13 20 32 SDC325 R125 25-01280

175 4 2 13 20 32 SDC325 N125 25-0206

200 3 5.9 13 20 32 SDC200 C125 25-0204

200 4 5.9 13 20 32 SDC140 C125 25-0466

D W X T S H Grit Conc. Stock Code

200 4 2 13 20 32 CBN B200 R125 25-0203

25

12V9

D U X T S H Grit Conc. Stock Code

100 10 2 20 45 31.75 SDC230 R100 25-2033

100 10 3 20 45 31.75 SDC120 R100 25-0142

100 10 3 20 45 31.75 SDC325 R100 25-0102

26

14A1


Stock Code

200 2 6 10 140 20 SDC200 N100 7087

200 2 6 5 140 60 SDC140 R100 7090

200 3 6 5 160 60 SDC200 R100 25-0348

200 4 6 5 160 60 SDC200 R100 7089

D U X T J H Grit Conc. Stock Code

200 3 6 5 160 60 CBN B140 R100 7131

200 4 6 5 160 60 CBN B140 R100 7092

200 4 6 5 150 31.75 CBN B140 R100 25-0214

27

14AA1


Stock Code

125 2.5+2.5 8 10 95 32 SDC120/325 R125/100 25-012521

150 2.5+2.5 8 10 125 32 SDC140/325 R100/75 25-01250

200 2.5+2.5 10 10 170 32 SDC140/325 R100/100 25-01300

28

14F1

D U R X J T H Grit Conc.

Stock Code

200 1.5 0.75 5 170 8 60 SDC230 R100 25-02085

200 2 1 6 150 5 60 SDC60 R100 25-02010

200 2 1 6 160 5 31.75 SDC200 R100 25-0249

200 3 1.5 5 140 12 31.75 SDC400 N100 25-02039

200 3 1.5 6 150 5 60 SDC200 R100 25-0238

250 3 1.5 6 200 10 32 SDC120 R100 25-0257

200 4 2 6 150 5 60 SDC200 R100 25-0295

D U R X J T H Grit Conc. Stock Code

150 1.5 0.75 6 125 8 32 CBN B80 R100 25-151

150 2 1 6 125 8 32 CBN B80 R100 25-162

150 2.5 1.25 6 125 8 32 CBN B80 R100 25-164

200 1.3 0.65 5 170 8 32 CBN B80 N125 25-02092

200 1.5 0.75 5 170 8 60 CBN B230 R100 25-02099

200 1.5 0.75 5 170 8 32 CBN B80 N125 25-02031

200 2 1 5 170 8 32 CBN B80 N125 25-02090

200 2 1 6 160 5 60 CBN B140 R100 25-0226

200 2 1 6 160 5 31.75 CBN B140 R100 25-0228

200 2.5 1.25 5 165 8 32 CBN B80 N125 25-02030

200 3 1.5 6 150 5 31.75 CBN B140 R100 25-0380

200 3 1.5 6 160 5 60 CBN B140 R100 25-0377

200 3 1.5 5 160 8 32 CBN B80 R125 25-02094

200 4 2 6 150 5 60 CBN B140 R100 25-0462

29

Diamond Dressing Tools

Asahi Diamond manufacture and supply a range of diamond dressers designed to meet the specific application demanded by industry. Diamond dresser type, shape and size is determined by the type of grinding machine used and the properties of the grinding wheel selected. Asahi technical staff are able to recommend which dresser is best suited for each specific application

30

Single Point Diamond Dressers

Asahi Diamond Single Point and Chisel Form Dressers have a carefully selected natural Diamond mounted firmly in the shank via sintering.

Standard Shank Dimensions:

12.7 dia x 150mm Custom Shanks available upon request.

Diamond Grade Carat Stock Code

A 0.25 1014

A 0.50 1015

A 1.00 1017

A 1.50 954

A 2.00 951

AA 0.50 1019

AA 1.00 955

31

Chisel Form Diamond Dressers

The shape of an Asahi Diamond Chisel Form Dresser changes depending on the machine and application. These Dressers have a wedge shape so that the corner of the Diamond does not touch the grinding wheel. The sharper point Diamonds provide better forming and usually have a radius of 0.2mm. The blade has a negative angle to increase strength. Custom specifications are available upon request.

Description Specification Stock Code

DF7 Chisel 40 degress x 0.125mm rad 953

DF7 Chisel 40 degrees x 0.250mm rad 1029





32

Blade Type Diamond Dressers

Asahi Diamond Blade Type Dressers are used for dressing steps on conventional wheels of various sizes. They are designed for use in line, step, radius and profile adjustment. Wheel shape, dimensions and grit, determine which size dresser is approriate for each application.


PBP-22-20 10W 1.5X 33L 8878-2

PBP-21-16 20W 1.5X 28L 998

33

Impregnated Diamond Dressers

Asahi Diamond Impregnated Dressers have Diamonds spread evenly in a metal binding material. Once the Diamonds are worn out, they are stripped and fresh, sharp Diamonds are exposed. Compared with traditional Single Point Dressers, the multiple Diamonds continuously work evenly on the grinding wheel providing optimal grinding conditions. Faster dressing feeds and dressing depths are achievable. Impregnated Dressers are economical and are a reliable choice of dressing tool.

Wheel Grain Size Grit Symbol

54 grit and coarser C

60 – 80 grit M

90 grit and finer F

Description Diamond Section

Shank Grit Stock Code

BD130C 15 dia 11 dia x 50mm C 20-110

BD130C 15 dia 9.53 dia x 50mm C 966

PBP 1-16 6.35 x 19.05mm 11 dia x 25mm C 999-1

PBP 1-16 6.35 x 19.05mm 12.7 dia x 100mm C 999

PBP 1-16 6.35 x 19.05mm Morse Taper 1 C 999MT1

PBP 2-16 4 x 9.5mm 12.7 dia x 50mm C 7795

PBP 3-16 6.35 x 12.7mm 9.35 dia x 50mm C 20-300

PBP 3-16 6.35 x 12.7mm 11 dia x 50mm C 20-100

PBP 3-16 6.35 x 12.7mm 12.7 dia x 50mm C 4801

PBP 3S-16 6.35 x 12.7mm (15 deg.) 11.11 dia x 38mm C CD-0029

PBP 7-16 6.35 dia 8 dia x 50mm C 1003

PBP 7-16 6.35 dia 12.7 dia x 50mm C 1003A

PBP 7-20 6.35 dia 11.11 dia x 55mm M 1004A

PBP 7-20 6.35 dia 12 dia x 30mm M 1004

PBP 8-16 9.35 dia 9.53 dia x 50mm C 963D

PBP 8-16 9.35 dia 11.11 dia x 60mm C 963

PBP 8-16 9.35 dia 12.7 dia x 50mm C 963A

PBP 8-20 9.53 dia 11.08 dia x 38mm M 2083

PBP 8S-20 9.53 dia (15 deg.) 12 dia x 50mm M 963E

PBP 9-20 4 dia 8 dia x 35mm M 961

PBP 10-20 5 dia 11.11 dia x 25mm M 3812

PBP 17 6.35 dia 11.11 dia x 25mm * 1007

* used for truing resin bond CBN wheels

34

Multipoint Diamond Dressers

Asahi Diamond Multipoint Dressers have several small Diamonds rigidly mounted in a pattern. Longer tool life is obtained because several Diamond points are in contact with the wheel, reducing pressure on each point. Multipoint Dressers are particularly suited for rough finishes used in conical grinding, inner-surface grinding, centre-less grinding. Finishing and dressing of convex surfaces and the side of grinding wheels.


Multi Point DM 4 5 Diamonds x 3 Row 970

35

Handheld Dressers

Asahi Diamond Handheld Dressers are a simple way of dressing conventional grinding wheels. Impregnated Handidressers provide a longer tool life by exposing fresh layers of Diamond as older worn Diamonds fall out.

Description Stock Code

Impregnated Handidresser Light Duty 1043

Impregnated Handidresser Heavy Duty 1044

Electroplated T-Dresser 5156

36

Electroplated Files

Asahi Diamond stocks a wide range of high quality Diamond and CBN electroplated engineers files. These files can be used in the timber, injection molding, tool making and engineering industries as well as within the medical field. They are recommended for machining cemented carbide and hardened steel moulds. - Standard fine grit files are 140mm long with 70mm electroplated Diamond section. - Standard coarse files are 200mm long with 70mm electroplated Diamond section. Diamond and CBN files are available in a five piece set.

When ordering CBN files please add ‘CBN’ to the end of stock code.

Description Type Mesh Stock Code

NF-1 Flat Fine D76 900

NF-4 Triangle Fine D76 903

NF-5 Square Fine D76 904

NF-6 Round Fine D76 905

NF-7 Half Round Fine D76 906

5 Piece Set Coarse 26-05

NF

1

NF

4

NF

5

NF

6

NF

7

37

Internal Grinders

1A1W

Asahi Diamond Internal Grinders are used for small diameter machining with jig grinders and high speed grinders. Diamond or CBN can be electroplated to any desired profile. This gives Internal Grinders a wide range of applications. Metal bond and resin bond grinders are available upon request. When ordering CBN Internal Grinders please add ‘CBN’ to end of stock code.

D

(mm) T

(mm) d

(mm) L

(mm) Mesh

Stock Code

1 4 3.175 50 150 21A06

1.5 4 3.175 50 150 21A10

2 4 3.175 50 150 21A14

2.5 4 3.175 50 150 21A18

3 4 3.175 50 150 21A22

3.5 4 3.175 50 150 21A26

4 4 3.175 50 150 21A30

4.5 4 3.175 50 150 21A34

5 4 3.175 50 150 21A38

5.5 8 6.35 75 100 21A40

6 8 6.35 75 100 21A42

7 8 6.35 75 100 21A46

8 8 6.35 75 100 21A50

9 8 6.35 75 100 21A54

10 8 6.35 75 100 21A58

12 8 6.35 75 100 21A62

15 8 6.35 75 100 21A66

20 8 6.35 75 100 21A68

25 8 6.35 75 100 21A70

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Countersink Tools 90 deg

Asahi Diamond plated Countersinks are designed to countersink holes in materials such as glass, quartz, composites, graphite epoxy, carbon, boron, fiberglass, marble and other non-ferrous materials.

Diameter Shank Type Stock Code

30mm dia Plain 7513

40mm dia Plain 6380

50mm dia Plain 7610

65mm dia Plain 6728S

75mm dia Plain 26-0075

30mm dia Habit 26-0030

40mm dia Habit 6380/H

50mm dia Habit 6726

65mm dia Habit 6728

75mm dia Habit 26-0075H

39

Metal Bond Core Drills

Overall Length: 75mm Barrel Length: 32mm Wall Thickness: 1.0mm

Metal Bond Core Drills are suitable for drilling glass, ceramics and natural stone. All Metal Bond Drills are supplied standard with a Habit Shank. Euro Shank is available upon request. Intermediate sizes from 3.0 to 110mm not listed below are also available.

Diameter Shank Type Stock Code

5 Habit 5415

10 Habit 5416

15 Habit 5406

20 Habit 5403

25 Habit 8404

30 Habit 5409

35 Habit 5410

40 Habit 4014

50 Habit 5411

60 Habit 9367

65 Habit 5405

70 Habit 5412

80 Habit 8673

90 Habit 5419

100 Habit 5445

110 Habit 5446

40

PCD and CBN Inserts and Tools

Asahi Diamond manufacture and stock a range of PCD and CBN (cubic boron nitride or Borazon) machining tools and inserts used in various manufacturing industries. - PCD has high performance in machining abrasive non-metallic and non-ferrous materials.

- CBN is used to machine hardened steels, cast iron, powdered metals and super alloys. With higher material removal rates, faster speeds and feeds and increased tool life, PCD and CBN products provide significant productivity and cost savings.


Insert only 3mm cutting length 3886




Complete Tool 3mm cutting length 4536




PCD Button Insert 9.53 dia x 3.2mm 3170

PCD Button Insert 12.7 dia x 3.2mm 6217

CBN Button Insert 9.53 dia x 3.2mm no k-land 7775A

CBN Button Insert 9.53 dia x 3.2mm 20 deg x 0.2mm k-land 7775



CBN Square Insert 9.5mm 0.8R 9271

CBN Square Insert 12.7mm 7 deg side clearance 9272

CBN Triangle Insert 9.53mm 0.8R (15mm side) 7670

41

Diamond Lapping Compound

Premium ‘SS’ Range

- Available in 5 gram syringes. - Water or oil soluble. - All compounds supplied in HIGH CONCENTRATION.

Stock Code

Code Mesh Micron Colour Recommendation

66A06 SS-0.25H 100000 0 - 0.5 Grey Ultra fine metallographic finish.

66A14 SS-1H 14000 0 - 2 Grey Mirror finishes on tungsten carbide and hard steels.

66A20 SS-2H 11000 1 - 3 Pink

6A24 SS-3H 8000 2 - 4 Yellow

Good fast polish on tungsten carbide and many final polishing operations but not fine enough

to produce metallographic finishes.

66A28 SS-4H 6500 3 - 5 Yellow

66A36 SS-6H 4000 2 - 6 Orange

66A44 SS-8H 2300 6 - 10 Green

66A46 SS-9H 1800 6 - 12 Green Medium surface finish on tungsten carbide and pre-polishing or removing scratches on

sapphire and ruby. 66A54 SS-15H 1200 10 - 20 Pale Blue

66A62 SS-18H 1100 15 - 20 Dark Blue Rapid stock removal, good surface finish on

tungsten carbide and steels. 66A72 SS-25H 800 20 - 30 Red

66A76 SS-30H 600 22 - 36 Red

Rapid stock removal on tungsten carbide and hardened steels.

66A92 SS-45H 450 40 - 50 Brown

66A98 SS-60H 270 50 - 70 Purple

66B08 SS-90H 230 75 - 110 Purple Very rapid stock removal and roughing operations

on tungsten carbide, hard steels and cermet.

42

Grinding Wheel Care and Practical Application

Please consider the following information when using Diamond and CBN Wheels. Doing so will provide an environment for the best grinding performance

and service life of your Asahi wheel.

43

Wheel Mounting After removing the previous wheel the mounting arbor or flange should be cleaned and checked to ensure that there are no burrs or score marks on any of the wheel bearing surfaces.

NOTE: Paper washers should never be used as packing materials. Set the balancing weights on the arbor or flange to such a position that they are equidistant from each other. Locate the wheel onto the arbor or flange and tighten the locknut sufficiently, allowing the wheel to move only when lightly tapped. Using a dial indicator gauge and moving the wheel by hand, the periphery is gently tapped with a soft mallet or wooden block until minimum run-out is achieved. It should be possible to tap the wheel to within 0.01mm of running true. Extreme care should be taken when tapping ceramic bonded wheels as they are by nature non resilient and are likely to fracture when subjected to physical shock.

Tighten the locknut or bolts and clock the wheel again to check that it has not moved during tightening.

44

Truing and Dressing Truing Diamond Wheels The wheel is trued using a brake truing device as follows:

The truing device is positioned so that the axis of its spindle is parallel to that of the machine bed or chuck, and directly beneath the Diamond wheel to be trued. (Fig 1).

The device is then passed across the wheel face using the cross feed. This is repeated and the Diamond wheel bought down onto the truing wheel in increments of 0.01mm applied at each side of the wheel. (Fig 2).

This process ensures that the Diamond wheel will be correctly trued with minimum wastage of time and Diamond.

Once running perfectly true, wheels should then be balanced on its arbor or flanges either statically or dynamically.

It is important to note that it is far more economical to true with a proper truing device than to let the wheel run-in.

If the measured run-out of the wheel is 0.01mm it is only necessary to remove that amount to achieve running truth. However, to let the wheel run-in it may remove 10x that amount and still not be running true or in balance.

If the wheel is resin bonded it is now ready for work. Ceramic and metal bonded wheels further require dressing to enable the wheel to operate at maximum efficiency.

45

Truing CBN Wheels Resin bonded CBN Wheels are trued using a Diamond dresser (PBP-17 type, S/C 1007) as follows:

The Dresser is held in a conventional holder and must be set on the centre line of the wheel.

Approx 0.015mm deep light cuts are taken across the face, until face is trued right across.

If the face of the trued wheel is glazed up and won’t grind efficiently you must dress the wheel in order to expose the CBN particles.

Metal bonded Wheels must be trued using a brake truing device with a silicon carbide wheel. Follow the same process as described for truing Diamond Wheels.

Dressing Diamond and CBN Wheels Use a grade A80-GV aluminum oxide stick (S/C 9652). For best practice, the stick should be held mechanically and fed into the wheel. Care should be taken that the dressing action is evenly applied over the full face of the wheel. If the dressing stick is held by hand it will follow the contours of the wheel. As there are invariably differences in bond hardness round the periphery of the wheel, the stick will tend to remove material preferentially promoting run-out. Even a balanced wheel may run out of true if the dressing stick is held by hand. The wheel is now ready for grinding. In some cases dressing may be necessary to remove build up of braze or steel from the surface of the wheel during its life.

46

Storage

Diamond and CBN Wheels should be carefully stored in their own box or kept on their own arbor.

Machine

Machines should be rigid, well maintained and free of vibration. Particular attention should be given to the running truth of the spindle and the condition of the spindle bearings.

Cutting Fluids

Diamond and CBN Wheels perform best when wet. Coolant measurably increases tool life, surface finish and grinding ability. Pure oil is the best coolant; however, if not available water soluble oil can also be used. Supplying coolant directly to the exact grinding point is most effective. Wheels which are to be used without coolant require a bond composition specific for dry grinding. This bond can be recommended by Asahi technical engineering staff.

Speeds

Peripheral grinding speeds vary according to the working condition - Speeds greatly influence performance. It is impossible to provide peripheral speeds for every conceivable circumstance, however, Asahi recommends the following general guidelines:

Bond Diamond

Wet Dry CBN

Wet Dry

Resin 17 – 30 m/sec 12 – 17 m/sec 25 – 40 m/sec 13 – 25 m/sec

Metal 12 – 18 m/sec 9 – 12 m/sec 13 – 25 m/sec

47

Speed Chart Wheel Speed Conversion Chart (RPM)

Diameter (mm) (in.)

22.9 M/S (4,500

s.f.p.m) RPM

25.4 M/S (5,000

s.f.p.m) RPM

28.0 M/S (5,500

s.f.p.m) RPM

30.5 M/S (6,000 s.f.p.m)

RPM

25.4 1 17,189 19,098 21,008 22,918

50.8 2 8,594 9,549 10,504 11,459

76.2 3 5,729 6,366 7,003 7,639

101.6 4 4,297 4,775 5,252 5,729

127 5 3,438 3,820 4,202 4,584

152.4 6 2,865 3,183 3,501 3,820

177.8 7 2,455 2,728 3,001 3,274

203.2 8 2,148 2,387 2,626 2,865

254 10 1,719 1,910 2,101 2,292

304.8 12 1,432 1,591 1,751 1,910

355.6 14 1,228 1,364 1,500 1,637

406.4 16 1,074 1,194 1,313 1,432

457.2 18 955 1,061 1,167 1,273

408 20 859 955 1,050 1,146

558.8 22 781 868 955 1,042

609.6 24 716 796 875 955

Diameter (mm) (in.)

33.0 M/S (6,500

s.f.p.m) RPM

35.6 M/S (7,000

s.f.p.m) RPM

38.1 M/S (7,500

s.f.p.m) RPM

40.6 M/S (8,000 s.f.p.m)

RPM

25.4 1 24,828 26,737 28,647 30,558

50.8 2 12,414 13,368 14,328 15,278

76.5 3 8,276 8,913 9,549 10,186

101.6 4 6,207 6,685 7,162 7,640

127.0 5 4,966 5,348 5,730 6,112

152.4 6 4,138 4,456 4,775 5,092

177.8 7 3,547 3,820 4,092 4,366

203.2 8 3,103 3,342 3,580 3,820

254 10 2,483 2,674 2,865 3,056

304.8 12 2,069 2,228 2,386 2,546

355.6 14 1,773 1,910 2,046 2,182

406.4 16 1,552 1,672 1,791 1,910

457.2 18 1,379 1,485 1,591 1,698

508.2 20 1,241 1,337 1,432 1,528

558.8 22 1,128 1,215 1,302 1,388

609.6 24 1,034 1,115 1,194 1,274

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Wheel Enquiry Form

Company General Info Current Tool

Name Supplier

Product Shape

Size

Machine Bond Resin/Metal/Electroplated/Vitrified

Type Spec

Make Usage / method

Model Unit price

Issue

Grinding Condition Tool life

Grinding mode Automatic / Hand Surface finish

Coolant Accuracy

Rpm

Peripheral speed

Comments

Feed rate

Depth of cut mm / pass

Total stock removal

Dressing tool

Work Piece Sketch

Application

Material

Hardness

Size / shape

Surface finish

Accuracy

Please return completed forms to [email protected] or fax 02 9977 8313

mailto:[email protected]

49

Notes…

Product Catalogue - Asahi Diamond · A grinding enquiry sheet is included on the last page of this...

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